ABSTRACT Pulsed current Micro Plasma Arc Welding is used to joint thin sheets of AISI 304L sheets, which are used in manufacturing of metallic bellows and diaphragms. In this article the effects of pulsing current parameters on weld pool geometry namely front width, back width, front height and back height of pulsed current micro plasma arc welded AISI 304L stainless steel sheets was analyzed. Four factors, five levels, central composite design was used to develop mathematical models, incorporating pulsed current parameters and weld pool geometry. The mathematical models have been developed by Response Surface Method. The adequacy of the models was checked by ANOVA technique. Variation of output responses with input process variables are discussed. By using the developed mathematical models, weld pool geometry parameters can be predicted.
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